Trim component for a base of a vehicle seat and method of manufacturing the trim component

ABSTRACT

A trim component for a vehicle seat base includes a center portion and first and second side portions. The center portion includes a center inner panel that can face a frame of the seat and a center outer panel that can to be visible within a passenger cabin of the vehicle. The center outer panel includes a flexible material and covers the center inner panel. The first and second side portions are fixed on opposite sides of the center portion. Each of the first and second side portions includes a side inner panel that can face the frame of the seat and a side outer panel that can be visible within the passenger cabin. The side outer panel includes the flexible material and covers the side inner panel. The trim component can be fixed to a back of the seat to conceal at least a portion of the frame.

INTRODUCTION

The information provided in this section is for the purpose of generallypresenting the context of the disclosure. Work of the presently namedinventors, to the extent it is described in this section, as well asaspects of the description that may not otherwise qualify as prior artat the time of filing, are neither expressly nor impliedly admitted asprior art against the present disclosure.

The present disclosure relates to a trim component for a base of avehicle seat and a method of manufacturing the trim component.

Vehicle seats include a cushion portion, a back portion, and a frameextending through the cushion portion and the back portion. The frame isfixed to the vehicle, for example at the vehicle floor. The framesupports the cushion portion and the back portion. Each portiongenerally includes a foam component supported by the frame and an outerlayer covering the foam. Some vehicle seats also include one or moretrim components. For example, a toe kick may be provided at a base of aback of the vehicle seat.

SUMMARY

A trim component for a base of a seat in a vehicle according to theprinciples of the present disclosure includes a center portion and firstand second side portions. The center portion includes a center innerpanel that can face a frame of the seat and a center outer panel thatcan to be visible within a passenger cabin of the vehicle. The centerouter panel includes a flexible material and covers the center innerpanel. The first and second side portions are fixed on opposite sides ofthe center portion. Each of the first and second side portions includesa side inner panel that can face the frame of the seat and a side outerpanel that can be visible within the passenger cabin. The side outerpanel includes the flexible material and covers the side inner panel.The trim component can be fixed to a back of the seat so that the trimcomponent conceals at least a portion of the frame of the seat.

In one aspect, each of the first and second side portions includes afirst region and a second region. The first region can project away fromthe center portion in an aft direction with respect to the seat. Thesecond region extends between the first region and the center portion. Adistance between a bottom edge of the center portion and first andsecond bottom edges of the respective first and second side portions inthe first region is greater than or equal to 10 mm and less than orequal to 50 mm in a direction parallel to a floor of the vehicle whenthe trim component is fixed to the back of the seat.

In one aspect, the back of the seat defines a first plane. The centerportion defines a second plane when the trim component is fixed to theback of the seat. Rearmost surfaces of the first and second sideportions define a third plane when the trim component is fixed to theback of the seat. A first angle between the second plane and the firstplane is less than a second angle between the third plane and the firstplane.

In one aspect, the first angle is less than or equal to 165°.

In one aspect, the center portion directly engages the frame of theseat.

In one aspect, the center inner panel and the side inner panels of thefirst and second side portions each include a plastic material.

In one aspect, the flexible material is selected from the groupconsisting of:

carpet, leather, suede, vinyl, and cloth.

In one aspect, the trim component further includes an elastic strapfixed to an edge of the center portion. The elastic strap can be fixedto the frame of the seat.

A seat for a vehicle according to the principles of the presentdisclosure includes a seat cushion portion, a seat back portion, aframe, and a trim component. The seat cushion portion can support anoccupant sitting on the seat cushion portion. The seat cushion portionincludes a cushion foam component and a cushion outer layer covering thecushion foam component. The seat back portion can support a back of theoccupant sitting on the seat cushion portion. The seat back portionincludes a back foam component and a back outer layer covering the backfoam component. The frame can be fixed to a floor of the vehicle thatsupports the seat cushion portion and the seat back portion. The frameis disposed at least partially within the cushion outer layer and theback outer layer. The trim component engages the frame. The trimcomponent has a first edge fixed to the seat back portion. A centerportion of the trim component forms an angle of greater than 0° withrespect to a plane perpendicular to the floor of the vehicle. A bottomedge of the center portion is disposed forward of a top edge of thecenter portion with respect to the seat. The trim component conceals atleast a portion of the frame.

In one aspect, the center portion of the trim component includes acenter inner panel facing the frame and a center outer panel visiblewithin a passenger cabin of the vehicle. The center outer panel coversthe center inner panel. The trim component further includes first andsecond side portions fixed on opposite sides of the center portion. Eachof the first and second side portions includes a side inner panel facingthe frame and a side outer panel visible within the passenger cabin. Theside outer panel covers the side inner panel.

In one aspect, the first and second side portions at least partiallywrap around respective first and second side shields of the frame toconceal the side shields from view with respect to an area directlybehind the seat.

In one aspect, the trim component directly engages a cross-member of theframe.

In one aspect, the cushion foam component and the back foam componentcan remain engaged with one another when the seat back portion ispivoted between 20° forward of a design position with respect to theseat cushion portion and 40° rearward of the design position withrespect to the seat cushion portion.

In one aspect, a back of the frame of the seat defines a plane and theback foam component is disposed entirely on one side of the plane.

In one aspect, a back of the frame of the seat defines a plane and thecushion foam component is disposed entirely on one side of the plane.

In one aspect, the seat cushion portion further includes a scrim havinga first edge fixed to the cushion foam component and a second edge fixedto the frame of the seat. The scrim can limit movement of the cushionfoam component with respect to the frame of the seat.

In one aspect, the trim component further includes an elastic strapfixed to a second edge of the trim component opposite the first edge ofthe trim component. The elastic strap can be fixed to the frame of thevehicle.

A method of manufacturing a trim component for a base of a seat in avehicle according to the principles of the present disclosure includesassembling a center portion of the trim component. Assembling the centerportion of the trim component includes placing a plastic center panel ona surface of a flexible center panel and sewing the plastic center panelto the flexible center panel. The method further includes assembling afirst side portion of the trim component by placing a first plastic sidepanel on a surface of a first flexible side panel and sewing the firstplastic side panel to the first flexible side panel. The method furtherincludes assembling a second side portion of the trim component byplacing a second plastic side panel on a surface of a second flexibleside panel and sewing the second plastic side panel to the secondflexible side panel. The method further includes joining the centerportion and the first and second side portions by disposing the centerportion between the first and second side portions and first and secondsewing inner edges of the first and second side portions to respectivefirst and second outer edges of the center portion. The method furtherincludes fixing the trim component to a back of the seat so that theplastic center panel and the plastic side panels are disposed toward aframe of the seat. The flexible center panel and the flexible sidepanels cover the respective plastic center panel and plastic sidepanels. The trim component conceals at least a portion of the frame ofthe seat.

In one aspect, the assembling the center portion of the trim componentincludes wrapping a portion of the flexible center panel around an edgeof the plastic center panel to sandwich the edge of the plastic centerpanel within a pocket formed by the flexible center panel and sewing theplastic center panel to the flexible center panel at the pocket of theflexible center panel. The assembling each side portion includeswrapping a portion of the flexible side panel around an edge of theplastic side panel to sandwich the edge of the plastic side panel withina pocket formed by the flexible side panel and sewing the plastic sidepanel to the flexible side panel at the pocket of the flexible sidepanel.

In one aspect, the assembling the center portion of the trim componentfurther includes fixing an elastic strap to a bottom edge of theflexible center panel. The fixing the trim component to the back of theseat includes fixing a top edge of the trim component to the back of theseat and fixing the elastic strap the frame of the seat.

Further areas of applicability of the present disclosure will becomeapparent from the detailed description, the claims and the drawings. Thedetailed description and specific examples are intended for purposes ofillustration only and are not intended to limit the scope of thedisclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a perspective view of a back of a vehicle seat according tocertain aspects of the present disclosure;

FIG. 2 is a perspective view of a trim component of the vehicle seat ofFIG. 1;

FIG. 3 is a perspective view of an underside of the trim component ofFIG. 2;

FIG. 4 is a partial perspective view of an underside of the vehicle seatof FIG. 1;

FIG. 5 is a partial sectional view of the vehicle seat of FIG. 1 takenat line 3-3 of FIG. 1;

FIG. 6 is a perspective view of the trim component of FIG. 2 engaging aside shield of a vehicle frame;

FIG. 7 is a plan view of the vehicle seat of FIG. 1;

FIG. 8 is a plan view of another vehicle seat;

FIGS. 9A-9B are sectional views of a cushion portion of the vehicle seatof FIG. 1;

FIG. 10 is a flowchart depicting a method of manufacturing the trimcomponent of FIG. 2; and

FIG. 11 is a partial exploded view of the underside of the trimcomponent of FIG. 2, the trim component being disassembled.

In the drawings, reference numbers may be reused to identify similarand/or identical elements.

DETAILED DESCRIPTION

As discussed above, vehicle seats include a cushion portion and a backportion that are both attached to a frame. The cushion portion supportsan occupant seated on the cushion portion and the back portion supportsthe back of the occupant seated on the cushion portion. The vehicle seatcan also include various trim components, such as a toe kick. The toekick may be fixed to a back of the vehicle seat near the base or bottomof the vehicle seat. The toe kick may at least partially conceal theseat frame, wiring, closeouts, and gaps between the cushion portion andthe back portion.

In one example, a planar toe kick extends straight across the base ofthe vehicle seat in a cross-car direction. The toe kick is aligned witha plane defined by a rear surface of a back portion of a seat or plasticside shields. The toe kick has an outside surface that is visible by apassenger in a passenger cabin of the vehicle and an inside surface thatis disposed toward a front of the seat. A position and orientation ofthe toe kick are limited by components of the cushion portion. Morespecifically, the toe kick contacts or abuts a foam component of thecushion portion that extends beyond a frame of the seat toward a back ofthe seat. The orientation of the toe kick, and more particularly itsalignment with the back portion of the seat, limits floor space in thearea behind the vehicle seat. Limited floor space may be problematic,for example, when a passenger is seated behind the vehicle seat (e.g.,when the vehicle seat is in a front row of seats and a passenger isseated in a second row of seats). The planar toe kick wraps around abottom portion of the vehicle seat and can appear bulky and/orunstructured.

In another example, a molded toe kick has a more structured appearancewhen compared to the planar toe kick described above. The molded toekick is thermoformed, and therefore requires specialized tooling tomanufacture. Furthermore, the rigid structure of the molded toe kicklimits its applicability to certain sizes of vehicle seats and/orcertain vehicle programs. Thus, each seat design or vehicle program mayrequire unique tooling to manufacture the molded toe kick.

In various aspects, the present disclosure provides a contoured trimcomponent or toe kick including flexible fabric outer panels andreinforcing plastic inner panels. The toe kick may include a centerportion and two side portion disposed on either side of the centerportion. The toe kick may be fixed to a back portion of a vehicle seatnear the bottom or base of the vehicle seat. More specifically, the toekick may include a top edge that is fixed to an outer layer, such as afabric cover, of the seat back portion. The toe kick may include abottom edge that wraps around a bottom of the seat and fastens to aframe of the seat within a seat cushion portion.

The back portion and the cushion portion of the vehicle seat may eachinclude a foam component. The foam may have a reduced volume or sizecompared to the foam of the vehicle seat having the planar toe kick. Forexample, the foam may be disposed entirely on one side of a planedefined by a back of the seat frame such that it does not extend beyondthe seat frame toward a rear of the seat. That is, the foam may bedisposed entirely in front of the plane. Thus, the orientation of thetoe kick is not limited by the foam components. The reduced foam volumemay also contribute to an overall weight reduction of the vehicle.

The toe kick may conform to an outer boundary of the seat frame tomaximize foot space in an area behind the seat. The toe kick may wraparound the bottom of the seat and engage portions of the seat frame tocreate a sculpted appearance. More particularly, the side portions ofthe toe kick may abut a plastic shield fixed to the seat frame and thecenter portion may engage a cross-member of the seat frame. The centerportion may be angled inward toward a front of the seat to create theextra foot space. The side portions may project in a rearward directionwith respect to the seat, conforming to the plastic shields and givingthe toe kick the aesthetically-pleasing contoured appearance.

In various aspects, the present disclosure also provides a method ofmanufacturing the toe kick. The method includes assembling the centerportion of the toe kick, assembling the side portions of the toe kick,joining the side portions to the center portion, and fixing the toe kickto the back of the seat. Assembling each of the center portion and theside portions may include sewing a plastic reinforcing panel to anunderside of a flexible outer panel. Assembling the center portion mayalso include fixing one or more elastic straps to an edge of the centerportion. Fixing the toe kick to the vehicle seat may include fixing atop edge of the toe kick to the seat back portion, such as by sewing,and fixing a bottom edge of the toe kick to the seat cushion portion orthe frame using the elastic strap. Unlike the molded toe kick,specialized tooling is not required. Therefore the toe kick manufacturedin accordance with the method of the present disclosure may beuniversally applicable to a variety of seats and vehicle programs.

Referring to FIG. 1, an example seat assembly according to certainaspects of the present disclosure is provided. The seat assembly may bea vehicle seat 10 disposed in a passenger cabin of a vehicle. Thevehicle seat 10 includes a cushion portion 12, a back portion 14, and aheadrest 16. The cushion portion 12 supports an occupant seated on thecushion portion 12. The back portion 14 supports a back of the occupantseated on the cushion portion 12. The headrest 16 supports a back of ahead of the occupant seated on the cushion portion 12.

The cushion portion 12 and the back portion 14 are supported by a frame(see frame 76 of FIG. 4). The frame is fixed to the vehicle, such as toa floor of the vehicle. The frame may be directly fixed to the floor orthe frame may alternatively slidably engage tracks 18 that are fixed tothe floor, as shown. The seat 10 may be movable in forward 19 and aft 20directions with respect to the seat.

As will be described in greater detail below, each of the cushionportion 12 and the back portion 14 includes a foam component (see foamcomponents 120, 122 of FIG. 7). The cushion portion 12 and the backportion 14 also include respective outer layers 21, 22. The outer layers21, 22 may include a soft material, such as cloth or leather. Portionsof the outer layers 21, 22 may also include a hard material, such asplastic. For example, a back or rear side 24 of the back portion 14 orsides 26 of the cushion portion 12 may include the hard material.

The vehicle seat 10 further includes one or more trim components 28,such as a toe kick 30. The toe kick 30 at least partially covers theseat frame, as viewed from an area of the passenger cabin located behindthe seat 10. With reference to FIGS. 2-3, the toe kick 30 includes acenter portion 40, a first side portion 42-1, and a second side portion42-2 (collectively referred to as the “side portions”). The centerportion 40 is disposed between the first side portion 42-1 and thesecond side portion 42-2. The center portion 40 is fixed to the firstand second side portions 42-1, 42-2 at first and second seams 44-1,44-2, respectively.

The center portion 40 is angled inward toward a front of the seat 10(e.g., in the forward direction 19). The first and second side portions42-1, 42-2 project outward with respect to the center portion 40 towarda rear of the seat 10 (e.g., in the aft direction 20). The first sideportion 42-1 includes a first back region 46-1 and a first connectingregion 48-1. The second side portion 42-2 includes a second back region46-1 and a second commenting region 48-2. The toe kick 30 is contouredto a portion of a back of the seat frame. The first and second backregions 46-1, 46-2 of the first and second side portions 42-1, 42-2engage respective first and second plastic shields fixed to the seatframe (see, e.g., first plastic shield 78-1 of FIG. 4). The centerportion 40 engages the seat frame (see cross-member 80 of FIG. 5). Invarious aspects, the first and second side portions 42-1, 42-2 maydirectly engage the respective first and second plastic shields and thecenter portion 40 may directly engage the cross-member of the seatframe. The first and second connecting regions 48-1, 48-2 of the firstand second side portions 42-1, 42-2 extend between the respective firstand second back regions 46-1, 46-2 and the center portion 40.

The center portion 40 includes a center inner panel 50 and a centerouter panel 52. The first side portion 42-1 includes a first side innerpanel 54-1 and a first side outer panel 56-1. The second side portion42-2 includes a second side inner panel 54-2 and a second side outerpanel 56-2. The outer panels 52, 56-1, 56-2 are disposed on top of orover the respective inner panels 50, 54-1, 54-2. The inner panels 50,54-1, 54-2 face the seat frame so that they are disposed forward of therespective outer panels 52, 56-1, 56-2 (e.g., in the forward direction19 with respect to the seat 10). That is, the inner panels 50, 54-1,54-2 are exposed on an underside 58 of the toe kick 30 (FIG. 3). Theouter panels 52, 56-1, 56-2 cover the respective inner panels 50, 54-1,54-2 so that the inner panels 50, 54-1, 54-2 are not visible from withinthe passenger cabin. The outer panels 52, 56-1, 56-2 are disposedrearward of the respective inner panels 50, 54-1, 54-2 (e.g., in the aftdirection 20 with respect to the seat). The outer panels 52, 56-1, 56-2are visible from within the passenger cabin, and more particularly, froman area behind the vehicle seat 10. That is, the outer panels 52, 56-1,56-2 are exposed on an outside 60 of the toe kick 30 (FIG. 2).

The inner panels 50, 54-1, 45-2 serve as a reinforcing layer to makeportions of the toe kick 30 rigid and structured in appearance. Theinner panels 50, 54-1, 54-2 include a plastic material. In variousaspects, the inner panels 50, 54-1, 54-2 may be referred to as theplastic center panel 50 and the plastic side panels 54-1, 54-2. Theplastic material is flat. The plastic material has a thickness ofgreater than or equal to 0.5 mm and less than or equal to 1.5 mm,optionally 1 mm, by way of non-limiting example. The center inner panel50 and the side inner panels 54-1, 54-2 may all include the same plasticmaterial.

The outer panels 52, 56-1, 56-2 conceal the inner panels 50, 54-1, 54-2to improve an appearance of the toe kick 30. The outer panels 52, 56-1,56-2 include a flexible material. In various aspects, the outer panels52, 56-1, 56-2 may be referred to as the flexible center panel 52 andthe flexible side panels 56-1, 56-2. The flexible material may becarpet, leather, suede, vinyl, or cloth, by way of non-limiting example.The flexible material for the outer panels 52, 56-1, 56-2 may beselected from the group consisting of: carpet, leather, suede, vinyl,cloth, and combinations thereof. The center outer panel 52 and the sideouter panels 56-1, 56-2 may all include the same flexible material. Invarious aspects, the center outer panel 52 may include a first flexiblematerial and the side outer panels 56-1, 56-2 may include a distinctsecond flexible material.

The first and second side inner panels 54-1, 54-2 are disposed withinthe respective first and second back regions 46-1, 46-2 of the first andsecond side portions 42-1, 42-2. The first and second side inner panels54-1, 54-2 may be disposed entirely within the respective first andsecond back regions 46-1, 46-2 so that the first and second connectingregions 48-1, 48-2 remain flexible to contour with the seat frame. Incontrast, the first and second back regions 46-1, 46-2 of the first andsecond side portions 42-1, 42-2 and the center portion 40 are reinforcedto maintain a structure and shape of the toe kick 30. For example, thetoe kick 30 may remain structured when the occupant seated behind thevehicle seat 10 rests his or her feet on the toe kick 30. The innerpanels 50, 54-1, 54-2 may not directly contact one another.

A first or top edge of the toe kick 30 is fixed to the seat back portion14. The center outer panel 52 includes a top edge 62. The first andsecond side outer panels 56-1, 56-2 includes respective first and secondtop edges 64-1, 64-2. The top edges 62, 64-1, 64-2 of the outer panels52, 56-1, 56-2 are fixed to the outer layer 22 of the seat back portion14. For example, the outer panels 52, 56-1, 56-2 may be sewn to theouter layer 22 when the outer layer 22 is a soft material, such asleather or cloth.

A second or bottom edge 66 of the toe kick 30 is sewn to one or moreelastic straps 68. As a non-limiting example, the one or more elasticstraps 68 may include two elastic straps 68. Each elastic strap 68includes ends 70 that are fixed to the bottom edge 66 of the toe kick 30to form loops. Each elastic strap 68 may also include a fastener 72. Thefastener 72 may be a 25 mm J-retainer, by way of non-limiting example.The fastener 72 may loosely slip along the elastic strap 68.

Referring to FIG. 4, the fastener 72 hooks around a portion of asuspension mat 74 within the cushion portion 12 of the vehicle seat 10.The elastic straps 68 are stretched to pull the center portion 40 in theforward direction 19 (FIG. 1) toward the front of the seat 10. Whencenter portion 40 is pulled forward, the first and second side portions42-1, 42-2 are also pulled forward until the underside 58 of the toekick 30 engages a frame 76. More specifically, the first side portion42-1 engages a first plastic shield 78-1 of the frame 76 and the secondside portion 42-2 engages a second plastic shield (not shown) of theframe. The center portion 40 engages a cross-member 80 of the frame 76,which may be a metal cross-member. The suspension mat 74 is fixed to theframe 76. Thus, the toe kick 30 is fixed to the frame through thesuspension mat 74. In various aspects, the center portion 40 maydirectly engage the cross-member of the frame (FIG. 5). The toe kick 30may be pulled taut over a back of the frame 76 to give the toe kick 30 acontoured or sculpted appearance.

With reference to FIG. 5, the center portion 40 of the toe kick 30 maybe in direct contact with the cross-member 80 of the frame 76. The backor rear side 24 of the back portion 14 defines a first plane 90. Thecenter portion 40 of the toe kick 30 defines a second plane 92. Therearmost surfaces (i.e., surfaces of the first and second back regions46-1, 46-2 of the first and second side portions 42-1, 42-2) of thefirst and second side portions 42-1, 42-2 of the toe kick 30 define athird plane 94.

A first angle 96 is formed between the first plane 90 and the secondplane 92. A second angle 98 is formed between the first plane 90 and thethird plane 94. A third angle 100 is formed between the second plane 92and the third plane 94. A magnitude of the first angle 96 is less than amagnitude of the second angle 98. Thus, the center portion 40 is angledfurther inward toward the front of the seat 10 (e.g., in the forwarddirection 19) when compared to the first and second side portions 42-1,42-2. In various aspects, the center portion 40 may form an angle ofgreater than 0° with respect to a plane perpendicular to the floor ofthe vehicle.

The first angle 96 may be less than or equal to 165°, optionally lessthan or equal to 160°, optionally less than or equal to 155°, andoptionally less than or equal to 150°. In various aspects, the firstangle 96 is greater than or equal to 135° and less than or equal to165°, optionally greater than or equal to 140° and less than or equal to160°, optionally greater than or equal to 145° and less than or equal to155°, and optionally 150°. The second angle 98 may be greater than 165°,and optionally greater than or equal to 170°. The third angle 100 may begreater than or equal to 5°, optionally greater than or equal to 10°,optionally greater than or equal to 15°, and optionally greater than orequal to 20°.

A distance 102 is defined between first and second bottom edges 104-1,104-2 of the first and second back regions 46-1, 46-2 of the first andsecond side portions 42-1, 42-2 and a bottom edge 106 of the centerportion 40. The distance 102 may be measured in a direction parallel tothe vehicle floor. The distance 102 may be less than or equal to 50 mm,optionally greater than or equal to 10 mm and less than or equal to 50mm, optionally greater than or equal to 15 mm and less than or equal to50 mm, optionally greater than or equal to 15 mm and less than or equalto 35 mm, optionally greater than or equal to 20 mm and less than orequal to 30 mm, optionally greater than or equal to 23 mm and less thanor equal to 27 mm, and optionally 25 mm. In various aspects, thedistance may be greater than or equal to 15 mm, optionally greater thanor equal to 20 mm, and optionally greater than or equal to 25 mm. Thetoe kick 30 in accordance with the present disclosure may providegreater than or equal to about 15 mm foot space when compared to thestraight, unstructured toe kick described above.

With reference to FIG. 6, the toe kick 30 may at least partially wraparound the first and second side shields 78-1 (FIG. 4), 78-2. The firstside portion 42-1 may include a first top region 110-1 and a first sideregion (not shown). The second side portion 42-2 may include a secondtop region 110-2 and a second side region 112-2. The first and secondtop regions 110-1, 110-2 are disposed above respective first and secondback regions 46-1, 46-2 (i.e., closer to the seat back portion 14). Thefirst top region 110-1 wraps around the first side shield 78-1,following a contour of a first edge (not shown) of the first side shield78-1. In a similar manner, the second top region 110-2 wraps around thesecond side shield 78-2, following a contour of a second edge 114-2 ofthe second side shield 78-2. The first side region is disposed outboardof the first back region 46-1 with respect to the seta 10. The firstside region at least wraps partially around the first edge of the firstside shield 78-1. The second side region 112-2 is disposed outboard ofthe second back region 46-2 with respect to the seat. The second sideregion 112-2 at least partially wraps around the second edge 114-2 ofthe second side shield 78-2. The side regions 112 at least partiallyconceal the side shields 78-1, 78-2 as viewed from an area behind theseat 10. In various aspects, the side regions 112 fully conceal the sideshields 78-1, 78-2 as viewed from the area behind the seat 10.

Referring to FIG. 7, the seat cushion portion 12 includes the outerlayer 21, a cushion foam component 121, and the frame 76, including thecross-member 80. The seat back portion 14 includes the outer layer 22, aback foam component 122, and the frame 76. The seat 10 also includes thetoe kick 30. The toe kick 30 extends from the rear side 24 of the seatback portion 14 to the cross-member 80 of the frame.

The foam components 121, 122 are disposed entirely on one side of aframe plane 124 defined by a back of the seat frame 76 when the seat 10is in the design position. More particularly, the foam components 121,122 are disposed frontward (e.g., in the forward direction 19) of theframe plane 124. The foam components 121, 122 may be disposed entirelyin front of the frame plane 124 such that neither foam component 121,122 extends beyond the frame 76 when the seat 10 is in the designposition. The foam components 121, 122 are sized and shaped to ensurethat they remain in contact with one another during rotation of the seatback portion 14 with respect to the seat cushion portion 12 (e.g., theseat back portion 14 is pivoted between 20° forward of the designposition and 40° rearward of the design position with respect to thecushion portion 12). The design position refers to the orientation ofthe cushion portion 12 and the back portion 14 with respect to thevehicle (e.g., the floor) and to one another prior to the user adjustingheight, angle, or location of the cushion and back portions 12, 14. Thedesign position includes a set of predetermined values set by the seator vehicle manufacturer.

FIG. 8 shows another vehicle seat 130 for reference. The vehicle seat130 includes a frame 132, cushion portion 134, and a back portion 136.The cushion portion 134 includes an outer layer 138 and a foam component140. The back portion 136 includes an outer layer 142 and a foamcomponent 144. The foam components 140, 144 have a smaller volumecompared to the foam components 121, 122 of the seat 10 in accordancewith the present disclosure. Portions 146 of each foam component 140,144, represented by a dashed line, are present in the reference vehicleseat 130 and absent from the vehicle seat 10 of the present disclosure.The seat 130 further includes a toe kick 148. A position of the toe kick148 is limited by the foam components 140, 144, which extend beyond aframe plane 150 defined by a back of the vehicle frame when the seat 130is in the design position. In contrast, the reduced-size or trimmed foamcomponents 121, 122 of the seat 10 of FIG. 7 enable the bottom edge 66of the toe kick 30 to be pivoted in the forward direction 19 (FIG. 1) toincrease the floor space behind the seat 10.

With reference to FIGS. 9A-9B, the seat cushion portion 12 may furtherinclude an anchor, such as a scrim 160. As discussed above, it isadvantageous for the cushion foam component 121 and the back foamcomponent 122 to remain in contact when the back portion 14 rotates withrespect to the cushion portion 12. A first edge 162 of the scrim 160 isfixed to the suspension mat 74 by one or more clips 164. A second edge166 of the scrim 160 opposite the first edge 162 of the scrim 160 isfixed to the cushion foam component 121. The second edge 166 of thescrim 160 may be fixed to the cushion foam component 121, for example,by molding or sewing in place. The scrim 160 can prevent or reducesliding of the cushion foam component 121 with respect to the suspensionmat 74 to increase contact between the cushion foam component 121 andthe back foam component 122.

Referring to FIGS. 10-11, a method of manufacturing the toe kick 30 isprovided. The method begins at 180. At 180, the center portion 40 isformed by joining the inner panel 50 to the center outer panel 52 andthe elastic straps 68 (FIGS. 3-4). The center inner panel 50 is placedon an underside surface 182 of the center outer panel 52. A bottomportion adjacent to the bottom edge 184 of the center outer panel 52 isfolded over a bottom edge 186 of the center inner panel 50 so that thebottom edge 186 of the center inner panel 50 is disposed within a firstpocket (not shown) formed by folding the center outer panel 52. Thebottom edge 186 of the center inner panel 50 is sandwiched within thefirst pocket. The ends 70 of the elastic straps 68 (FIG. 3) are placedon top of the first pocket formed by the center outer panel 52. A firsthem is created by sewing the center outer panel 52 to the center innerpanel 50 and the ends 70 of the elastic straps 68 along the bottom edge186 of the center inner panel 50. In alternative embodiments, theelastic straps 68 may be attached in a separate step from forming thefirst hem.

At 190, the first and second side inner panels 54-1, 54-2 are joined tothe respective first and second side outer panels 56-1, 56-1 to form thefirst and second side portions 42-1, 42-1. The first and second sideinner panels 54-1, 54-2 are placed on respective first and secondunderside surfaces 192-1, 192-2 of the first and second side outerpanels 56-1, 56-2. Bottom portions of first and second bottom edges194-1, 194-2 of the first and second side outer panels 56-1, 56-2 arefolded over respective first and second bottom edges 196-1, 196-2 of thefirst and second side inner panels 54-1, 54-2 so that the first andsecond bottom edges 196-1, 196-2 of the first and second side innerpanels 54-1, 54-2 are disposed within respective second and thirdpockets (not shown) formed by folding the first and second side outerpanels 56-1, 56-2. The first bottom edge 194-1 of the first side innerpanel 54-1 is sandwiched within the second pocket. The second bottomedge 194-2 of the second side inner panel 54-2 is sandwiched within thethird pocket. Second and third hems are created by sewing the first andsecond side outer panels 56-1, 56-2 to respective side inner panels54-1, 54-2.

First and second outside portions of first and second outside edges198-1, 198-2 of the first and second side outer panels 56-1, 56-2 arefolded over respective first and second outside edges 210-1, 210-2 ofthe first and second side inner panels 54-1, 54-2 so that the first andsecond outside edges 210-1, 210-2 of the first and second side innerpanels 54-1, 54-2 are disposed within respective fourth and fifthpockets (not shown) formed by folding the first and second side outerpanels 56-1, 56-2. The first outside edge 200-1 of the first side innerpanel 54-1 is sandwiched within the fourth pocket. The second outsideedge 200-2 of the second side inner panel 54-2 is sandwiched within thefifth pocket. Fourth and fifth hems are created by sewing the first andsecond side outer panels 56-1, 56-2 to respective first and second sideinner panels 54-1, 54-2. The first hems, second hems, third hems, fourthhems, and fifth hems may be created by back-sewing to prevent the threadfrom unraveling.

At 204, the center portion 40 is joined to the first and second sideportions 42-1, 42-2 to form the toe kick 30. More specifically, firstand second outside edges 206-1, 206-2 of center outer panel 52 arejoined to first and second inside edges 208-1, 208-2 of the first andsecond side outer panels 56-1, 56-2. The edges 206, 208-1, 208-2 may bejoined by sewing to form the first and second seams 44-1, 44-2.

At 212, the toe kick 30 is fixed to the seat back portion 14. When theouter layer 22 is a flexible material, such as cloth or leather, the topedges 62, 64-1, 64-2 of the outer panels 52, 56-1, 56-2 are fixed to thebottom edge 214 of the outer layer 22. The top edges 62, 64-1, 64-2 ofthe outer panels 52, 56-1, 56-2 of the toe kick 30 may be fixed to thebottom edge 214 of the outer layer 22 of the seat back portion 14, forexample, by sewing. When the outer layer 22 is a rigid material, such asplastic, the top edges 62, 64-1, 64-2 of the outer panels 52, 56-1, 56-2of the toe kick 30 may be fixed to the seat frame 76 within the seatback portion 14. The outer layer 22 may be fixed to the seat backportion 14 so that it overlaps the top edges 62, 64-1, 64-2 of the outerpanels 52, 56-1, 56-2 of the toe kick 30.

At 218, the bottom edge 66 of the toe kick 30 is fixed to the seatcushion portion 12. More specifically, the fasteners 72 on the straps 68of the toe kick 30 are fixed to the suspension mat 74. Thus, the toekick 30 extends around the bottom or base of the back of the vehicleseat 10, at least partially covering the seat frame 76.

The toe kick 30 may be used in an automobile, such as on vehicle seatsdisposed in front of other vehicle seats or storage areas. The toe kick30 may be used in other non-automotive vehicle applications, such as forairplane seats, train seats, bus seats, and agricultural equipmentseats, by way of non-limiting example. Although the toe kick 30 is shownas described as being assembled to the vehicle seat 10, alternativenon-vehicle uses are also contemplated. For example, the toe kick 30 maybe used for seats in airports, waiting rooms, classrooms, and offices.

The foregoing description is merely illustrative in nature and is in noway intended to limit the disclosure, its application, or uses. Thebroad teachings of the disclosure can be implemented in a variety offorms. Therefore, while this disclosure includes particular examples,the true scope of the disclosure should not be so limited since othermodifications will become apparent upon a study of the drawings, thespecification, and the following claims. It should be understood thatone or more steps within a method may be executed in different order (orconcurrently) without altering the principles of the present disclosure.Further, although each of the embodiments is described above as havingcertain features, any one or more of those features described withrespect to any embodiment of the disclosure can be implemented in and/orcombined with features of any of the other embodiments, even if thatcombination is not explicitly described. In other words, the describedembodiments are not mutually exclusive, and permutations of one or moreembodiments with one another remain within the scope of this disclosure.

Although the terms first, second, third, etc. may be used herein todescribe various elements, components, regions, layers and/or sections,these elements, components, regions, layers and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, layer or section from another region,layer or section. Terms such as “first,” “second,” and other numericalterms when used herein do not imply a sequence or order unless clearlyindicated by the context. Thus, a first element, component, region,layer or section discussed below could be termed a second element,component, region, layer or section without departing from the teachingsof the example embodiments.

Spatial and functional relationships between elements (for example,between modules, circuit elements, semiconductor layers, etc.) aredescribed using various terms, including “connected,” “engaged,”“coupled,” “adjacent,” “next to,” “on top of,” “above,” “below,” and“disposed.” Unless explicitly described as being “direct,” when arelationship between first and second elements is described in the abovedisclosure, that relationship can be a direct relationship where noother intervening elements are present between the first and secondelements, but can also be an indirect relationship where one or moreintervening elements are present (either spatially or functionally)between the first and second elements. As used herein, the phrase atleast one of A, B, and C should be construed to mean a logical (A OR BOR C), using a non-exclusive logical OR, and should not be construed tomean “at least one of A, at least one of B, and at least one of C.”

None of the elements recited in the claims are intended to be ameans-plus-function element within the meaning of 35 U.S.C. § 112(f)unless an element is expressly recited using the phrase “means for,” orin the case of a method claim using the phrases “operation for” or “stepfor.”

What is claimed is:
 1. A seat for a vehicle comprising: a seat cushionportion configured to support an occupant sitting on the seat cushionportion, the seat cushion portion including a cushion foam component anda cushion outer layer covering the cushion foam component; a seat backportion configured to support a back of the occupant sitting on the seatcushion portion, the seat back portion including a back foam componentand a back outer layer covering the back foam component; a frameconfigured to be fixed to a floor of the vehicle that supports the seatcushion portion and the seat back portion, the frame being disposed atleast partially within the cushion outer layer and the back outer layer;and a trim component engaging the frame and having a first edge fixed tothe seat back portion, the trim component including a center portion, afirst side portion, and a second side portion, the center portionforming an angle of greater than 0° with respect to a planeperpendicular to the floor of the vehicle such that a bottom edge of thecenter portion is disposed forward of a top edge of the center portionwith respect to the seat, wherein: the trim component conceals at leasta portion of the frame; the center portion includes a center inner panelfacing the frame and a center outer panel visible within a passengercabin of the vehicle, the center outer panel covering the center innerpanel; and the first side portion and the second side portion are fixedon opposite sides of the center portion, each of the first side portionand the second side portion including a side inner panel facing theframe and a side outer panel visible within the passenger cabin, theside outer panel covering the side inner panel.
 2. The seat of claim 1wherein: each of the first and second side portions includes a firstregion configured to project away from the center portion in an aftdirection with respect to the seat and a second region extending betweenthe first region and the center portion; and a distance between a bottomedge of the center portion and first and second bottom edges of therespective first and second side portions in the first region is greaterthan or equal to 10 mm and less than or equal to 50 mm in a directionparallel to a floor of the vehicle when the trim component is fixed tothe back of the seat.
 3. The seat of claim 1 wherein: the back of theseat defines a first plane; the center portion defines a second planewhen the trim component is fixed to the back of the seat; rearmostsurfaces of the first and second side portions define a third plane whenthe trim component is fixed to the back of the seat; and a first anglebetween the second plane and the first plane is less than a second anglebetween the third plane and the first plane.
 4. The seat of claim 1wherein the center inner panel and the side inner panels include aplastic material.
 5. The seat of claim 1 wherein the center outer paneland the side outer panels include a flexible material selected from thegroup consisting of: carpet, leather, suede, vinyl, and cloth.
 6. Theseat of claim 1 wherein: the first side portion at least partially wrapsaround a first side shield of the frame to conceal the first side shieldfrom view with respect to an area directly behind the seat; and thesecond side portion at least partially wraps around a second side shieldof the frame to conceal the second side shield from view with respect tothe area.
 7. The seat of claim 1 wherein the trim component directlyengages a cross-member of the frame.
 8. A seat for a vehicle comprising:a seat cushion portion configured to support an occupant sitting on theseat cushion portion, the seat cushion portion including a cushion foamcomponent and a cushion outer layer covering the cushion foam component;a seat back portion configured to support a back of the occupant sittingon the seat cushion portion, the seat back portion including a back foamcomponent and a back outer layer covering the back foam component; aframe configured to be fixed to a floor of the vehicle that supports theseat cushion portion and the seat back portion, the frame being disposedat least partially within the cushion outer layer and the back outerlayer; and a trim component engaging the frame and having a first edgefixed to the seat back portion, the trim component including a centerportion forming an angle of greater than 0° with respect to a planeperpendicular to the floor of the vehicle such that a bottom edge of thecenter portion is disposed forward of a top edge of the center portionwith respect to the seat, wherein the cushion foam component and theback foam component are configured to remain engaged with one anotherwhen the seat back portion is pivoted between 20° forward of a designposition with respect to the seat cushion portion and 40° rearward ofthe design position with respect to the seat cushion portion.
 9. Theseat of claim 8 wherein a back of the frame of the seat defines a planeand the back foam component is disposed entirely on one side of theplane.
 10. The seat of claim 8 wherein a back of the frame of the seatdefines a plane and the cushion foam component is disposed entirely onone side of the plane.
 11. The seat of claim 10 wherein the seat cushionportion further includes a scrim having a first edge fixed to thecushion foam component and a second edge fixed to the frame of the seat,the scrim being configured to limit movement of the cushion foamcomponent with respect to the frame of the seat.
 12. A seat for avehicle comprising: a seat cushion portion configured to support anoccupant sitting on the seat cushion portion, the seat cushion portionincluding a cushion foam component and a cushion outer layer coveringthe cushion foam component; a seat back portion configured to support aback of the occupant sitting on the seat cushion portion, the seat backportion including a back foam component and a back outer layer coveringthe back foam component; a frame configured to be fixed to a floor ofthe vehicle that supports the seat cushion portion and the seat backportion, the frame being disposed at least partially within the cushionouter layer and the back outer layer; and a trim component engaging theframe and having a first edge fixed to the seat back portion, the trimcomponent including a center portion and an elastic strap, the centerportion forming an angle of greater than 0° with respect to a planeperpendicular to the floor of the vehicle such that a bottom edge of thecenter portion is disposed forward of a top edge of the center portionwith respect to the seat, the elastic strap being fixed to a second edgeof the trim component opposite the first edge of the trim component, theelastic strap being configured to be fixed to the frame of the vehicle.